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JP2000513769A - Mechanically reinforced nonwovens for the production of dimensionally stable molded parts - Google Patents

Mechanically reinforced nonwovens for the production of dimensionally stable molded parts

Info

Publication number
JP2000513769A
JP2000513769A JP53452996A JP53452996A JP2000513769A JP 2000513769 A JP2000513769 A JP 2000513769A JP 53452996 A JP53452996 A JP 53452996A JP 53452996 A JP53452996 A JP 53452996A JP 2000513769 A JP2000513769 A JP 2000513769A
Authority
JP
Japan
Prior art keywords
nonwoven fabric
mechanically reinforced
weight
fiber
fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
JP53452996A
Other languages
Japanese (ja)
Inventor
ポツラー、ベルンド
リーディガー、ヴォルフガング
Original Assignee
ローマン ゲーエムベーハー ウンド コー．カーゲー
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ローマン ゲーエムベーハー ウンド コー．カーゲー filed Critical ローマン ゲーエムベーハー ウンド コー．カーゲー
Publication of JP2000513769A publication Critical patent/JP2000513769A/en
Pending legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/006—Pressing and sintering powders, granules or fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5414—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres side-by-side
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D04H1/55—Polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/06—PE, i.e. polyethylene
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/638—Side-by-side multicomponent strand or fiber material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/682—Needled nonwoven fabric
    • Y10T442/684—Containing at least two chemically different strand or fiber materials
    • Y10T442/688—Containing polymeric strand or fiber material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/69—Autogenously bonded nonwoven fabric
    • Y10T442/692—Containing at least two chemically different strand or fiber materials

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Nonwoven Fabrics (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Woven Fabrics (AREA)
  • Manufacturing Of Multi-Layer Textile Fabrics (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)

Abstract

(57)【要約】 大きな転向角及び強度の変形の際、偏向点における破れ及び欠点を防ぐため、不織布は、数種の繊維成分からなり、圧力及び温度により、柔軟性のある寸法的に安定した成形品を形成する。付加的ＣｏＰＥＳ−繊維成分は、追加補助剤を使用することなく、他の繊維との積層を促進する。   (57) [Summary] In order to prevent tears and drawbacks at deflection points during deformations with large turning angles and strengths, the nonwoven fabric consists of several fiber components and forms flexible, dimensionally stable moldings under pressure and temperature. . The additional CoPES-fiber component facilitates lamination with other fibers without the use of additional auxiliaries.

Description

【発明の詳細な説明】 寸法安定性成形品製造用の機械的に強化された不織布 本発明は、寸法的に安定した柔軟性のある成形品製造用の機械的に強化された 不織布に関するものである。 用語『機械的に強化された不織布』は、ニードルパンチ法における、とげ付き 針の手段によって、又はスパンレース法によるジェット水流によって、或いはス テッチニッティング法におけるクーリア針(coulier needles)によって機械的に 強化される不織布を含むものと解釈される。これらの不織布は、例えば、ポリエ チレンテレフタレート繊維、又は異なる軟化点を持つポリエチレンテレフタレー トポリマーの複合繊維、或いはホモポリマーの混合繊維のような伸張された又は 部分的に伸張されたポリエステル繊維を使用して製造される。 成形用不織布の製造技術はいくつかある。例えば、いわゆる熱融着加工により 、ＰＥＳ−複合繊維の一部(コア・被覆)を有する粗いポリエステル繊維（ＰＥＳ ）から成るこれら不織布は、凝固後、圧力及び温度により変形される。前記複合 繊維の被覆層が溶融し始め、その後ポリエステル繊維及び複合繊維は交差部にお いて共に融着する。この方法は、定期刊行物「テクテクスティル テレグラム(Tec htextil Telegramm)」1991年、21号、3頁において記載されている。 特別な接着繊維成分を使用したＰＥＳ−スパンボンド不織布の製造では、別の 技術が見られる。これらは、圧力及び温度により、例えば、成形されたタフテッ ドカーぺット用の一次基布として使用される、変形深さ３５cmの成形パーツに加 工される（コンフェレンツ アインツェルベリヒト(Konferenz Einzelbericht)： テクスティリエン イム アオトモービル、コングレス デア ファオデーイー−ゲ ゼル．テクスティル ウント ベクライドゥング(Textilien im Automobil，Kongr ess der VDI-Gesell．Textil und Bekleidung)、1993、デュッセルドルフ(Duess eldorf)、1993年10月14日〜15日、9〜23頁）。 更に、機械的に強化された不織布マットは、３つの積層(被覆不織布−充填不 織布−被覆不織布)から成り、加熱により変形され、成形品用支持基布として使 用されるものとして知られている。この方法は、コンフェレンツ アインツェル ベリヒト(Konferenz Einzelbericht)：第32回インター．ケミーファーザーター グング(32nd Int．Chemiefasertagung)1993、ドルンビルン(Dornbirn)、オース トリア(Austria)、1993年9月22日〜24日、1〜25頁、書類番号68に記載されてい る。 周知の技術により、リサイクル可能な純度の高い等級の繊維材から成る成形品 の製造が可能となる。 これらの方法において、広範囲にわたる変形は得られるが、極端な転向角(def lection angle)及び複雑な形状を持つ場合、生地が偏向点(points of deflectio n)で破れる又は欠点を形成するといった、短所を有する。寸法的に安定した変形 を得るために、これらの不織布は、高度に強化されなければならず、それにより 、柔軟性の損失が生じる。 従って、本発明の目的は、５cm以上の間隔で、８０°以上の大きな変形角の場 合においてさえ、一方では高度に強化され、他方では破れることもなく欠点を形 成することもない、寸法的に安定した柔軟性のある成形品製造用の不織布を提供 することである。 並列複合繊維(side-by-side bicomponent fibers)は、二つのポリマー成分か らなり、丸型繊維の断面の各半分が一つのポリマーから成っている。 本発明によると、この目的は、前記の機械的に強化された不織布が、１６５〜 １７５℃の溶融範囲を有するホモポリマー非結晶性混合繊維を４０〜７５重量％ 及び並列複合繊維を１０〜４０重量％含むことにより達成される。 優れた変形性能、寸法安定性及びリサイクルされるという特性を確実なものに するため、更に本発明の実施形態により、前記不織布が、混合繊維を４５〜６５ 重量％及び並列複合繊維を２０〜３０重量％含むことが好ましいことが分かる。 ＰＥＳベースの混合繊維及びＰＥＳ／ＣｏＰＥＳベースの複合繊維が好ましい 。 変形性能は、例えば、繊度が３．３dtexで、繊維長が３８mmであるＰＥＳの充 填繊維によって維持される。別の実施形態によると、様々な材料との積層を促進 するために、ＰＥＳ混合繊維が最高２０重量％まで含まれる。１７０℃で、前記 繊維は、完全に溶融し、成形品に接着される。 前記の機械的に強化された不織布の更に有利な実施形態は、従属クレームの特 性により提供される。 ニードルパンチ法による強化が、特に好ましい。 本発明により達成され得る利点は、特に、１００℃以上においても、軽量且つ 強度に変形可能であり、並びに耐温度性を有し、リサイクルでき、偏向点で破れ ることも欠点を形成することもない、機械的に強化された不織布から成る成形品 を製造できるということにある。個々の需要によって、前記不織布は、所望され るあらゆる形状に簡単に適応され得る。強化法及び繊維組成は、実際の需要に適 応できる。 本発明の実施例を、以下詳細に渡って説明する。 カードを用いて、単位面積当たりの重量が均一な線維ウェブを、ＰＥＳ−混合 繊維４．５／５０(dtex/mm繊維長)を５０重量％、ＰＥＳ／ＣｏＰＥＳ−複合繊 維３．３／５０を２５重量％、ＰＥＳ−充填繊維３．３／３８を２０重量％及 びＰＥＳ−充填繊維１．７／３８を５重量％含む均質混合物から製造する。カー ド機及び横方向(transverse)の積層装置を通過すると、単位面積当たり重量２０ ０〜２５０g/m2の不織布が形成される。これは、各５０〜８０ステッチ/cm2の２ つの針突刺によるニードルパンチがわずかに与えられ、作り上げられ、そしてロ ーラでならされる。空気圧又は水圧プレスにより、変形が施される。前記成形板 は、約１８５〜１９０℃に加熱される。閉位置において、前記板の間の間隔は、 金型全体に渡り均一である（０．２〜１．５mm）。前記の機械的に強化された不 織布を、サイズに裁断し、金型に配置する。前記板を、約２０秒間、約２Ｎ/cm2 で押し付ける。挿入された不織布は、型締時間(約３〜５秒)の間、１３０℃まで ゆっくりと加熱される。前記２種類の成分が、異なった収縮特性を持つ事より、 前記複合繊維は、二金属性スプリングのように反応し、極端なスプリング式ケン 縮を形成する。これにより、縦及び横方向に、不織布の伸縮性が最高２００％ま で増加する。この効果により、不織布が偏向点で破れることは防がれる。完全に 閉鎖された金型で、前記混合繊維は、活性化され、前記繊維の交差部が接着され る。わずか一度の熱的負荷をかけると、非結晶性繊維は結晶化し、従って、「標 準」ＰＥＳ−繊維となる。このため、ＰＥＳ／ＣｏＰＥＳ−混合繊維の使用に比 べて、耐温度性が高い。Description: TECHNICAL FIELD The present invention relates to a mechanically reinforced nonwoven for the production of dimensionally stable and flexible molded articles. is there. The term `` mechanically reinforced nonwoven '' is mechanically reinforced by means of barbed needles in the needle punching process, by jet water jets in the spunlace process, or by coulier needles in the stitch knitting process. It is to be understood as including nonwoven fabrics to be made. These nonwoven fabrics are manufactured using, for example, stretched or partially stretched polyester fibers, such as polyethylene terephthalate fibers, or composite fibers of polyethylene terephthalate polymers having different softening points, or mixed fibers of homopolymers. Is done. There are several techniques for producing nonwoven fabrics for molding. For example, these nonwoven fabrics made of coarse polyester fibers (PES) having a part (core / coating) of PES-composite fibers are deformed by pressure and temperature after coagulation by so-called heat fusion processing. The composite fiber coating layer begins to melt, after which the polyester fiber and the composite fiber fuse together at the intersection. This method is described in the periodical Tectextil Telegramm, 1991, issue 21, p. Another technique is found in the production of PES-spunbond nonwovens using special adhesive fiber components. These are processed by pressure and temperature into molded parts with a deformation depth of 35 cm, for example used as primary backing for molded tufted cartons (Konferenz Einzelbericht): Textilien im Automobil, Kongress der der VDI-Gesell Textil und Bekleidung, 1993, Duess eldorf, October 14-15, 1993 Sun, pp. 9-23). Further, mechanically reinforced nonwoven mats are known to be composed of three laminates (coated nonwoven-filled nonwoven-coated nonwoven), deformed by heating, and used as a support base fabric for molded articles. This method is described in Konferenz Einzelbericht: 32nd Inter. Chemie asertagung (32nd Int. Chemiefasertagung) 1993, Dornbirn, Austria, September 22-24, 1993, pages 1-25, Document No. 68. Known techniques make it possible to produce recyclable molded articles of high-grade fibrous material. In these methods, a wide range of deformations can be obtained, but with extreme deflection angles and complex shapes, the disadvantages are that the fabric tears or forms defects at points of deflection. Having. In order to obtain dimensionally stable deformations, these nonwovens must be highly reinforced, resulting in a loss of flexibility. It is therefore an object of the present invention to provide, at intervals of 5 cm or more, even in the case of large deformation angles of 80 ° or more, on the one hand, a high degree of reinforcement, on the other hand, without breaking or forming defects, An object of the present invention is to provide a stable and flexible nonwoven fabric for producing a molded article. Side-by-side bicomponent fibers consist of two polymer components, each half of the cross-section of a round fiber consisting of one polymer. According to the present invention, the purpose is that the mechanically reinforced nonwoven comprises 40-75% by weight of a homopolymeric amorphous mixed fiber having a melting range of 165-175 ° C. and 10-40% by weight of the parallel conjugate fiber. % By weight. In order to ensure good deformability, dimensional stability and recyclable properties, it is further preferred according to an embodiment of the present invention that the nonwoven fabric comprises 45-65% by weight of mixed fibers and 20-30% by weight of parallel conjugate fibers. It is understood that it is preferable to contain the weight%. PES-based mixed fibers and PES / CoPES-based composite fibers are preferred. Deformation performance is maintained, for example, by PES filled fibers having a fineness of 3.3 dtex and a fiber length of 38 mm. According to another embodiment, up to 20% by weight PES blended fibers are included to facilitate lamination with various materials. At 170 ° C., the fibers are completely melted and adhered to the molding. Further advantageous embodiments of said mechanically reinforced nonwoven are provided by the features of the dependent claims. Strengthening by the needle punch method is particularly preferred. The advantages that can be achieved by the present invention are, in particular, light and strong deformable, even above 100 ° C., as well as temperature-resistant, recyclable, without breaking at the point of deflection or forming defects. A molded article made of a mechanically reinforced nonwoven fabric. Depending on the individual needs, the nonwoven can be easily adapted to any desired shape. The reinforcement method and fiber composition can be adapted to the actual demand. Embodiments of the present invention will be described in detail below. Using a card, a fibrous web having a uniform weight per unit area was prepared by mixing 50% by weight of PES-mixed fiber 4.5 / 50 (dtex / mm fiber length) and 3.3 / 50 of PES / CoPES-composite fiber. It is prepared from a homogeneous mixture containing 25% by weight, 20% by weight of PES-filled fiber 3.3 / 38 and 5% by weight of 1.7 / 38 PES-filled fiber. Upon passing through a carding machine and a transverse laminator, a nonwoven fabric weighing 200 to 250 g / m 2 per unit area is formed. It is slightly given, built up, and rolled with two needle piercing needle punches of 50-80 stitches / cm 2 each. The deformation is applied by a pneumatic or hydraulic press. The shaped plate is heated to about 185 to 190C. In the closed position, the spacing between the plates is uniform (0.2-1.5 mm) throughout the mold. The mechanically reinforced nonwoven is cut to size and placed in a mold. The plate is pressed at about 2 N / cm 2 for about 20 seconds. The inserted nonwoven is slowly heated to 130 ° C. during the mold closing time (about 3-5 seconds). Due to the different shrinkage properties of the two components, the composite fiber reacts like a bimetallic spring and forms an extreme spring-type shrink. This increases the stretch of the nonwoven in the machine and transverse directions up to a maximum of 200%. This effect prevents the nonwoven from breaking at the point of deflection. In a completely closed mold, the mixed fibers are activated and the intersections of the fibers are glued. With only one thermal load, the amorphous fibers crystallize and thus become "standard" PES-fibers. For this reason, temperature resistance is high compared with the use of a PES / CoPES-mixed fiber.

【手続補正書】特許法第１８４条の８第１項 【提出日】平成９年６月２７日（１９９７．６．２７） 【補正内容】 請求の範囲 １．機械的に強化され、軽量で、特に強度に変形可能であり、純度の高い等級の 、リサイクル可能な不織布の成形品であって、前記不織布が成分として、 １６５〜１７５℃の範囲の融点を有するホモポリマー非結晶性混合繊維を４０ 〜７５重量％、 ポリエステル（ＰＥＳ）及び共重合ポリエステル（ＣｏＰＥＳ）を含むサイド バイサイド複合繊維を１０〜４０重量％、 充填繊維を最高でも５０重量％まで、 混合繊維を最高でも２０重量％まで を含有することを特徴とする不織布の成形品。 ２．前記混合繊維が、純度の高いＰＥＳを含有することを特徴とする請求項１に 記載の機械的に強化された不織布。 ３．前記混合繊維が、ポリエチレンテレフタレート、特に１０〜１２重量％の結 晶部を有する非結晶ポリエチレンテレフタレートを含有することを特徴とする請 求項１又は２に記載の機械的に強化された不織布。 ４．前記混合繊維の前記ＰＥＳ部が、ホモポリマーポリエチレンテレフタレート を含有し、前記ＣｏＰＥＳ部がコポリマーポリエチレンテレフタレートを含有す ることを特徴とする請求項１から３の一つ又は複数項に記載の機械的に強化され た不織布。 ５．前記充填繊維がポリエチレンテレフタレートを含有することを特徴とする請 求項１に記載の機械的に強化された不織布。 ６．機械的に強化され、軽量で、特に強度に変形可能である不織布の成形品製造 方法であって、ホモポリマー非結晶性混合繊維を４０〜７５重量％、ＰＥＳ及び ＣｏＰＥＳを含む並列複合繊維を２０〜４０重量％、ポリエチレンテレフタレー トを含有する充填繊維を最高でも５０重量％まで、同様に混合繊維を最高でも２ ０重量％まで含む機械的に前もって作られ、強化された不織布が、交差部におい て共に溶融する前記繊維と共に、成形圧力下、加熱可能プレスの成形板の間で加 熱されることを特徴とする請求項１から５に記載の不織布の成形品製造方法。 ７．リサイクル可能な軽量成形品製造用の機械的に強化された不織布の使用方法 。[Procedure of Amendment] Article 184-8, Paragraph 1 of the Patent Act [Submission date] June 27, 1997 (1997.6.27) [Correction contents]                                The scope of the claims 1. Mechanically reinforced, lightweight, particularly strong deformable, high purity grade A molded article of recyclable non-woven fabric, wherein the non-woven fabric is a component,   A homopolymer amorphous mixed fiber having a melting point in the range of 165 to 175 ° C. ~ 75% by weight,   Side containing polyester (PES) and copolyester (CoPES) 10 to 40% by weight of biside composite fiber,   Filling fiber up to 50% by weight,   Up to 20% by weight of mixed fiber The molded article of nonwoven fabric characterized by containing. 2. 2. The method according to claim 1, wherein the mixed fiber contains high-purity PES. The non-woven fabric of any of the preceding claims. 3. The mixed fiber is polyethylene terephthalate, especially 10 to 12% by weight; A non-crystalline polyethylene terephthalate having a crystalline part The mechanically reinforced nonwoven fabric according to claim 1 or 2. 4. The PES portion of the mixed fiber is a homopolymer polyethylene terephthalate. And the CoPES portion contains a copolymer polyethylene terephthalate. 4. Mechanically reinforced according to one or more of claims 1 to 3, characterized in that Nonwoven. 5. The filling fiber contains polyethylene terephthalate. The non-woven fabric reinforced according to claim 1. 6. Manufacture of non-woven fabrics that are mechanically reinforced, lightweight and especially deformable A method comprising the steps of: adding 40 to 75% by weight of a homopolymer amorphous mixed fiber; 20-40% by weight of parallel composite fiber containing CoPES, polyethylene terephthalate Up to 50% by weight of filled fiber containing A mechanically prefabricated, reinforced non-woven fabric containing up to 0% by weight Together with the fibers, which melt together, under the forming pressure, between the forming plates of the heatable press. The method for producing a molded article of a nonwoven fabric according to claim 1, wherein the molded article is heated. 7. Use of a mechanically reinforced nonwoven fabric for the manufacture of lightweight recyclable moldings .

Claims (1)

【特許請求の範囲】 １．寸法的に安定した柔軟性のある成形品製造用の機械的に強化された不織布で あって、前記不織布が、１６５〜１７５℃の溶融範囲を有するホモポリマー非結 晶性混合繊維を４０〜７５重量％及び並列複合繊維を１０〜４０重量％含むこと を特徴とする不織布。 ２．変形後、前記繊維が共に溶融されることを特徴とする請求項１に記載の機械 的に強化された不織布。 ３．好ましくは混合繊維を４５〜６５重量％及び複合繊維を２０〜３０重量％含 有することを特徴とする請求項１又は２に記載の機械的に強化された不織布。 ４．前記複合繊維が、ＰＥＳ及びＣｏＰＥＳを含有することを特徴とする請求項 １から３の一つ又は複数項に記載の機械的に強化された不織布。 ５．前記混合繊維が、純度の高いＰＥＳを含有することを特徴とする請求項１か ら４の一つ又は複数項に記載の機械的に強化された不織布。 ６．前記混合繊維が、ポリエチレンテレフタレート、特に結晶部を１０〜１２重 量％有する非結晶ポリエチレンテレフタレートを含有することを特徴とする請求 項５に記載の機械的に強化された不織布。 ７．前記ＰＥＳ部が、ホモポリマーポリエチレンテレフタレートを含有し、前記 ＣｏＰＥＳ−部がコポリマーポリエチレンテレフタレートを含有することを特徴 とする請求項４に記載の機械的に強化された不織布。 ８．充填繊維を最高５０重量％まで含むことを特徴とする請求項１から７の一つ 又は複数項に記載の機械的に強化された不織布。 ９．前記充填繊維がポリエチレンテレフタレートを含有することを特徴とする請 求項８に記載の機械的に強化された不織布。 １０．混合繊維を最高２０重量％まで含むことを特徴とする請求項１から９の一 つ又は複数項に記載の機械的に強化された不織布。 １１．純度の高い等級のものであることを特徴とする請求項１から１０の一つ又 は複数項に記載の機械的に強化された不織布。 １２．不織布から成る成形品の製造方法であって、ホモポリマー非結晶性混合繊 維を４０〜７５重量％及び並列複合繊維を１０〜４０重量％含む機械的に強化さ れた不織布が、交差部において共に溶融する前記繊維と共に、成形圧力下、加熱 可能プレスの成形板の間で加熱されることを特徴とする製造方法。 １３．リサイクル可能な軽量成形品製造用の機械的に強化された不織布の使用。[Claims] 1. A mechanically reinforced non-woven fabric for the production of dimensionally stable and flexible molded parts Wherein the nonwoven fabric has a homopolymer non-consolidation having a melting range of 165 to 175 ° C. 40 to 75% by weight of crystalline mixed fiber and 10 to 40% by weight of parallel conjugate fiber Nonwoven fabric characterized by the following. 2. The machine of claim 1, wherein after deformation, the fibers are melted together. Reinforced nonwoven fabric. 3. Preferably, it contains 45 to 65% by weight of mixed fiber and 20 to 30% by weight of composite fiber. The mechanically reinforced nonwoven fabric according to claim 1, wherein the nonwoven fabric has a nonwoven fabric. 4. The said composite fiber contains PES and CoPES, The claim characterized by the above-mentioned. 4. The mechanically reinforced nonwoven fabric according to one or more of items 1 to 3. 5. The said mixed fiber contains high purity PES, The Claim 1 characterized by the above-mentioned. 5. The mechanically reinforced nonwoven fabric according to one or more of claims 4. 6. The mixed fiber has polyethylene terephthalate, particularly, a crystal part having 10 to 12 layers. Claims: 1. A non-crystalline polyethylene terephthalate having an amount of Item 6. A mechanically reinforced nonwoven fabric according to item 5. 7. The PES portion contains a homopolymer polyethylene terephthalate, CoPES-part contains copolymer polyethylene terephthalate The mechanically reinforced nonwoven fabric according to claim 4. 8. 8. The method as claimed in claim 1, wherein the filler fibers comprise up to 50% by weight. Or the non-woven fabric reinforced according to any of the above items. 9. The filling fiber contains polyethylene terephthalate. The mechanically reinforced nonwoven fabric according to claim 8. 10. 10. The method as claimed in claim 1, comprising up to 20% by weight of mixed fibers. A mechanically reinforced nonwoven fabric according to one or more of the preceding claims. 11. 11. One or more of claims 1 to 10, characterized in that they are of high purity grade. Is a mechanically reinforced nonwoven fabric according to any of the preceding claims. 12. A method for producing a molded article comprising a nonwoven fabric, comprising a homopolymer non-crystalline mixed fiber Mechanically reinforced containing 40-75% by weight of fiber and 10-40% by weight of parallel conjugate fiber The non-woven fabric is heated under molding pressure together with the fibers that melt together at the intersection. A manufacturing method characterized by heating between forming plates of a possible press. 13. Use of mechanically reinforced nonwovens for the manufacture of lightweight recyclable moldings.
JP53452996A 1995-05-18 1996-05-10 Mechanically reinforced nonwovens for the production of dimensionally stable molded parts Pending JP2000513769A (en)

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DE19518285.5 1995-05-18
DE19518285A DE19518285C2 (en) 1995-05-18 1995-05-18 Mechanically consolidated nonwoven fabric for the production of dimensionally stable molded parts
PCT/EP1996/001997 WO1996036755A1 (en) 1995-05-18 1996-05-10 Mechanically compacted non-woven material for use in the production of dimensionally stable mouldings

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DE19812925A1 (en) * 1998-03-24 1999-09-30 Asota Gmbh Easily recycled dimensionally stable moulded laminate especially for car carpet
DE19832721A1 (en) * 1998-07-21 2000-01-27 Sandler C H Gmbh Composite sheet for use as outer layer in an expanded foam sandwich comprises a natural fiber textile layer, an extensible layer, and a thermoplastic layer which penetrates into the other layers and acts as bonding agent
KR100729957B1 (en) * 2006-03-23 2007-06-19 한국바이린주식회사 Automobile nonwoven fabric interior material and manufacturing method
DE102006045069A1 (en) 2006-09-21 2008-04-03 Sandler Ag Multilayer nonwoven composite material and method for producing a multilayer nonwoven composite material
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US4883707A (en) * 1988-04-21 1989-11-28 James River Corporation High loft nonwoven fabric
US5198057A (en) * 1988-12-23 1993-03-30 Fiberweb North America, Inc. Rebulkable nonwoven fabric
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